$45.95
Yale Forklift B875 (GLP20-35VX, GDP20-35VX Europe) Service Manual - PDF
Yale Forklift B875 (GLP20-35VX, GDP20-35VX Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yale Forklift B875 (GLP20-35VX, GDP20-35VX Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 5414
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Yale Forklift B875 (GLP20-35VX, GDP20-35VX Europe) Service Manual – PDF DOWNLOAD
524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) UK EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524221866 9000YRM1112 (10 2020) UK EN 43
SECTION 9010 Operational Diagnostic Procedures 59
Group 05 – Operational Checkout 61
SECTION 9020 Engine 79
Group 10 – Principles of Operation 89
Group 30 – Observed Symptoms 287
Group 40 – Tests and Adjustments 389
SECTION 9030 Electrical System 421
Group 03 – General Maintenance and Diagnostic Data 445
Group 10 – Principles of Operation 539
Group 20 – Diagnostic Trouble Codes 563
Group 30 – Observed Symptoms 1535
SECTION 9040 Drive Train 1591
Group 10 – Principles of Operation 1595
Group 30 – Observed Symptoms 1651
Group 40 – Tests and Adjustments 1701
SECTION 9050 Hydraulic Systems 1711
Group 10 – Principles of Operation 1715
Group 30 – Observed Symptoms 1773
Group 33 – Observed Symptoms-Gear Pump 1775
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1863
Group 40 – Tests and Adjustments 1907
Group 43 – Tests and Adjustments-Gear Pump 1909
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1933
SECTION 9060 Operators Station 1951
Group 10 – Principles of Operation 1953
SECTION 9070 Front End (Mast) and Chassis 1989
Group 10 – Principles of Operation 1991
Group 30 – Observed Symptoms 2013
SECTION 9080 Supplementary Data 2071
Group 50 – Abbreviations and Acronyms 2073
Group 60 – Special Tools List 2081
Group 70 – Fault Mode Indicator Reference 2091
Group 80 – Supplier Specification Data 2093
524223754 0100YRM1120 (12 2012) UK EN 2097
toc 2097
Frame 2097
Safety Precautions Maintenance and Repair 2098
General 2101
Description 2101
Hood, Seat, and Side Covers Replacement 2102
Remove 2102
Install 2108
Steering Column 2113
Description 2113
Steering Column Repair 2113
Remove 2113
Disassemble 2115
Clean 2115
Inspect 2115
Assemble 2115
Install 2118
LPG Tank and Bracket Assembly 2118
Counterweight Replacement 2119
Remove 2119
Install 2122
Tow Pin, Remove and Install 2123
Overhead Guard Replacement 2123
Remove and Install 2123
LED Tail, Backup, and Brake Lights, Replace 2124
Operator Restraint System Replacement 2125
Description 2125
Automatic Locking Retractor (ALR) 2125
Emergency Locking Retractor (ELR) 2125
Engine Replacement 2127
Remove 2127
Install 2132
Transmission Replacement 2134
Remove Transmission with Iron Housing 2134
Install Transmission with Iron Housing 2136
Remove Transmission with Aluminum Housing 2136
Install Transmission with Aluminum Housing 2141
Throttle Pedal and Cable Adjustment 2144
Mazda Gas/LPG Engines With Basic Power Shift Transmission and El 2144
Mazda Gasoline Engine With Electronic Transmission 2146
Throttle Pedal Stop Adjustment 2147
Yanmar Diesel Engine With Basic Power Shift Transmission 2148
Yanmar Diesel Engine With Electronic Throttle 2148
Exhaust System Repair 2149
Lift Trucks With Counterweight Exhaust System 2149
Mazda Gas and LPG Engines 2149
Remove and Disassemble 2149
Inspect 2149
Assemble and Install 2149
Yanmar Diesel Engine 2151
Remove and Disassemble 2151
Inspect 2151
Assemble and Install 2151
Lift Trucks With Overhead Exhaust System 2153
Yanmar Diesel Engine 2153
Remove and Disassemble 2153
Inspect 2153
Assemble and Install 2154
Mazda Gas and LPG Engines 2156
Remove and Disassemble 2156
Inspect 2156
Assemble and Install 2156
Cooling System 2158
Description 2158
Hydraulic Filter Assembly Repair 2158
Remove 2158
Clean and Inspect 2159
Install 2159
Fuel and Hydraulic Tanks Repair 2160
Inspect 2160
Clean 2160
Steam Method of Cleaning 2160
Chemical Solution Method of Cleaning 2161
Additional Preparations for Repair 2161
Small Leaks, Repair 2161
Large Leaks, Repair 2161
Preparations for Use After Repair 2162
Safety Labels 2162
tables 2097
Table 1 Gas Spring Installation, Lift Truck Models GLP/GDP16VX, 2109
Table 2 Gas Spring Installation, Lift Truck Models GLP/GDP20-35 2111
Table 3 Weight of Counterweights, Lift Truck Models GLC20-35VX 2121
Table 4 Weight of Counterweights, Lift Truck Models GC/GLC030VX 2121
Table 5 Weight of Counterweights, Lift Truck Models GLP/GDP16-1 2121
Table 6 Weight of Counterweights, Lift Truck Models GLP/GDP20-3 2121
524223755 0600YRM1121 (12 2012) UK EN 2169
toc 2169
GM Engine Repair 2169
Safety Precautions Maintenance and Repair 2170
General 2175
Engine Serial Number 2175
Engine Removal and Installation 2177
Intake Manifold 2177
Remove 2177
Clean and Inspect 2178
Install 2178
Exhaust Manifold 2179
Remove 2179
Clean and Inspect 2179
Install 2179
Camshaft and Cylinder Head Repair 2180
Rocker Arm Cover 2180
Remove 2180
Install 2180
Camshaft Timing Pulley and/or Front Seal 2180
Remove 2180
Install 2181
Camshaft Carrier and Cylinder Head 2182
Remove 2182
Disassemble 2183
Camshaft Carrier 2183
Cylinder Head 2184
Clean and Inspect 2185
Camshaft Carrier 2185
Cylinder Head 2185
Valve and Valve Seat 2187
Assemble 2188
Cylinder Head 2188
Camshaft Carrier 2188
Install 2188
Timing Belt 2190
Timing Belt Front Cover 2190
Remove 2190
Install 2191
Timing Belt and Timing Belt Tensioner 2191
Remove 2191
Install 2192
Timing Belt Rear Cover 2193
Remove 2193
Install 2193
Lubrication System Repair 2194
Oil Pan 2194
Remove 2194
Install 2194
Oil Pump 2196
Remove 2196
Clean and Inspect 2197
Install 2198
Piston and Piston Rod Assemblies Repair 2198
Piston Rod Bearings, Replace 2198
Piston and Piston Rod Assemblies 2200
Remove 2200
Disassemble 2201
Pistons, Clean and Inspect 2202
Cylinder Bores, Inspect and Repair 2202
Piston Rings, Inspect 2203
Assemble 2204
Install 2204
Crankshaft and Main Bearings 2205
Crankshaft Timing Pulley and/or Front Seal 2205
Remove 2205
Install 2206
Crankshaft Rear Main Oil Seal 2207
Remove 2207
Install 2207
Crankshaft/RPM Sensor 2207
Remove 2207
Install 2208
Crankshaft Reluctor Wheel 2208
Remove and Install 2208
Crankshaft and Main Bearings 2208
Remove 2208
Inspect and Repair 2209
Bearing Selection 2210
Main Bearings and Journal Clearance, Check 2211
Install 2212
Flywheel and Flywheel Housing 2213
Remove 2213
Install 2213
Cooling System Repair 2214
Serpentine Belt 2214
Remove 2214
Inspect 2214
Install 2214
Water Pump 2215
Remove 2215
Inspect 2215
Install 2217
Thermostat 2218
Remove 2218
Check 2218
Install 2219
Thermostat Housing 2220
Remove 2220
Clean and Inspect 2220
Install 2220
Sensors and Switches 2222
Crankshaft Position (CKP) Sensor 2222
Remove 2222
Install 2222
Camshaft Position (CMP) Sensor 2222
Remove for Lift Trucks Built Before January, 2010 2222
Assembly 2222
Sensor Only 2222
Install for Lift Trucks Built Before January, 2010 2223
Assembly 2223
Sensor Only 2223
Remove for Lift Trucks Built After January, 2010 2224
Install for Lift Trucks Built After January, 2010 2224
Oil Pressure Sensor 2224
Remove 2224
Install 2224
Ignition System 2225
Spark Plug Wire Inspection 2225
Spark Plug Wire Replacement 2225
Remove 2225
Install 2226
Spark Plug Replacement 2226
Remove 2226
Install 2227
Spark Plug Inspection 2227
Usage 2227
Inspect 2227
Visual Inspection 2229
Coil Pack 2229
Remove 2229
Install 2229
Alternator Repair 2230
Alternator 2230
Remove 2230
Install 2230
Alternator Fuse, Replace 2230
Starter Repair 2231
Remove 2231
Install 2231
Engine Specifications 2232
Engine Data 2232
Cylinder Bore 2232
Piston 2232
Piston Rings 2233
Wrist Pin 2233
Crankshaft 2233
Piston Rod 2234
Camshaft and Camshaft Carrier 2234
Valve System 2234
Cylinder Head Warpage 2235
Lubrication System 2235
Cooling System 2235
Torque Specifications 2236
Special Tools 2237
524223756 0600YRM1122 (03 2020) UK EN 2243
General 2247
Serial Number 2248
Engine Removal and Installation 2248
Cylinder Head, Camshaft, and Valve Mechanism Repair 2248
Remove 2248
Clean 2251
Inspect and Repair 2251
Cylinder Head 2251
Rocker Shaft Assembly 2251
Camshaft 2252
Valve Guides 2253
Valve Seats 2253
Valves 2254
Valve Springs 2254
Install 2255
Crankshaft and Main Bearings Repair 2259
Remove 2259
Inspect and Repair 2260
Crankshaft 2260
Main Bearings 2260
Install 2261
Pistons and Connecting Rods Repair 2262
Remove and Disassemble 2262
Clean 2262
Inspect and Repair 2262
Pistons 2262
Piston Rings 2262
Connecting Rods and Bearings 2263
Assemble and Install 2263
Cylinder Block Repair 2265
Oil Pump Repair 2266
Remove 2266
Disassemble 2267
Clean 2267
Inspect 2267
Assemble 2268
Install 2268
Cooling System Repair 2270
Thermostat 2270
Replace 2270
Fan Assembly 2270
Remove and Disassemble 2270
Assemble and Install 2271
Water Pump 2271
Remove 2271
Install 2272
Flywheel and Ring Gear Repair 2273
Remove 2273
Install 2273
Valve Adjustment 2273
Compression Pressure Check 2275
Engine Timing Adjustment 2276
Engine Specifications 2276
Engine Data 2276
Engine Speeds 2276
2007, and Later, Emission Compliant Engines 2276
All Engines Except 2007, and Later, Emission Compliant Engines 2277
Thermostat 2277
Cylinder Head 2277
Valve Mechanism 2277
Camshaft 2278
Crankshaft 2278
Connecting Rods 2278
Cylinder Block 2279
Pistons 2279
Oil Pump 2279
Torque Specifications 2280
524223757 0700YRM1123 (06 2016) UK EN 2283
General 2287
Cooling System Checks 2287
Exhaust Leaks Into Cooling System 2287
Water Flow Restrictions in Radiator 2287
Radiator Hoses 2287
Water Pump 2288
Flushing the Cooling System 2288
Cooling System, Clean 2288
Radiator Replacement 2289
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2290
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2305
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2308
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2311
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2318
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2323
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2325
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2328
Fan Assembly Replacement 2340
Fan Removal 2340
Inspect 2355
Fan Installation 2355
524223758 0900YRM1124 (04 2018) UK EN 2361
General 2365
Hoses Replacement 2365
LPG Tank and Bracket Replacement 2365
Remove LPG Tank 2365
Install LPG Tank 2367
Remove LPG Bracket 2368
Install LPG Bracket 2370
Remove LPG Tank Bracket Alignment Pin 2370
Install LPG Tank Bracket Alignment Pin 2372
Fuel Filter Unit Repair 2372
Fuel Filter Element 2372
Remove 2372
Clean/Inspect 2373
Install 2373
Fuel Filter Housing 2373
Remove 2373
Disassemble 2374
Assemble 2374
Install 2375
Electronic Throttle Body Repair 2375
Electronic Throttle Body 2375
Remove 2375
Install 2376
Electronic Throttle Body Adapter Plate 2376
Remove 2376
Install 2376
Fuel Injector Repair 2376
Fuel Rail 2377
Remove for Lift Trucks Built Before January, 2010 2377
Install for Lift Trucks Built Before January, 2010 2378
Remove for Lift Trucks Built After January, 2010 2378
Install for Lift Trucks Built After January, 2010 2379
Fuel Injector for Lift Trucks Built Before January, 2010 2380
Remove 2380
Clean 2380
Install 2380
Fuel Injector Adapters for Lift Trucks Built Before January, 2010 2381
Remove 2381
Install 2383
Fuel Injectors and Adapters for Lift Trucks Built After January, 2010 2383
Remove 2383
Clean 2383
Install 2384
LPG Regulator Repair 2384
LPG Regulator 2384
Remove 2384
Install 2385
LPG Regulator Fuel Filter 2385
Remove 2385
Install 2386
Lock-Off Solenoid and Cartridge 2386
Remove 2386
Install 2387
Control System 2387
Electronic Control Unit (ECU) 2387
Remove 2387
Install 2389
Fuel Pump Relay 2389
Remove 2389
Install 2390
Injector Driver Module 2390
Remove 2390
Install 2391
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2391
Remove 2391
Install 2391
Engine Coolant Temperature (ECT) Sensor 2392
Remove 2392
Install 2392
Oxygen Sensor 2392
Remove 2392
Install 2393
Low LPG Pressure Switch 2393
Remove 2393
Install 2394
Exhaust System Repair 2395
Remove and Disassemble 2395
Inspect 2396
Assemble and Install 2396
LPG Fuel Testing 2397
General 2397
Available Fuel Tests 2397
Composition Test (ASTM D-2163) 2397
Ammonia Test (ASTM D-4490) 2397
Basic Nitrogen Test (ASTM UOP269-90) 2397
Residues Test (ASTM D-2158) 2397
Vapor Pressure Test (ASTM D-2598) 2398
Sulfur Compounds Test (ASTM D-5623) 2398
Methanol Test (ASTM D-4864) 2398
Copper Corrosion (ASTM D-1838) 2398
Where To Send LPG Fuel Samples For Testing 2398
524223759 0900YRM1125 (10 2005) UK EN 2401
toc 2401
LPG Fuel System 2401
Safety Precautions Maintenance and Repair 2402
General 2405
Hoses Replacement 2405
LPG Tank Replacement 2405
Remove 2405
Install 2407
Fuel Filter 2408
Remove 2408
Clean and Inspect 2408
Install 2409
Relief Valve Replacement 2410
Remove and Install 2410
Carburetor Repair 2410
Remove 2410
Disassemble 2410
Clean 2412
Assemble 2412
Install 2412
Fuel Injector Repair 2413
Remove 2413
Clean and Inspect 2413
Install 2413
Governor Repair 2413
Remove 2413
Install 2413
Regulator Repair 2414
Remove 2414
Install 2414
Control System 2415
Engine Control Unit (ECU) 2415
Remove 2415
Install 2416
Engine Coolant Temperature (ECT) Sensor 2416
Remove 2416
Install 2416
Camshaft Position (CMP) Sensor 2416
Voltage Check 2416
Intake Air Temperature (IAT) Sensor 2417
Remove 2417
Install 2417
Manifold Absolute Pressure (MAP) Sensor 2418
Remove 2418
Install 2418
Oxygen Sensor 2418
Remove 2418
Install 2418
Throttle Position (TP) Sensor 2419
Remove 2419
Install 2419
524223762 1300YRM1129 (11 2018) UK EN 2423
General 2427
Serial Number 2427
Charge Pump Repair 2427
Remove 2427
Inspect 2428
Install 2428
Torque Converter Replace 2428
Remove 2428
Install 2436
Front Cover Housing and Chain Drive Repair 2442
Remove 2442
Clean 2451
Inspect 2451
Install 2451
Clutch Packs Repair 2460
Remove and Disassemble 2460
Transmission, Remove and Disassemble 2460
Clean 2479
Inspect 2479
Assemble and Install 2480
Transmission, Assemble and Install 2488
Control Valve Repair 2494
Remove and Disassemble 2494
Clean 2498
Inspect 2498
Assemble and Install 2498
Foot Directional Control Pedal Repair 2499
Remove and Disassemble 2499
Assemble and Install 2503
Direction Control Lever 2504
Remove 2504
Install 2504
524223764 1600YRM1133 (07 2013) UK EN 2509
toc 2509
Steering Axle 2509
Safety Precautions Maintenance and Repair 2510
General 2513
Steering Axle Assembly Repair 2515
Remove 2515
Disassemble 2516
Clean 2524
Inspect 2524
Assemble 2524
Install 2530
Spindles, Bearings, and Tie Rods Repair 2532
Spindles and Bearings 2532
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2532
Remove 2532
Disassemble 2534
Clean 2535
Inspect 2535
Assemble 2535
Install 2536
Spindles and Bearings 2539
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2539
Remove and Disassemble 2539
Assemble and Install 2540
Tie Rods 2540
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2540
Remove 2540
Install 2541
Tie Rods 2542
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2542
Remove 2542
Install 2548
Steering Cylinder Repair 2548
Remove and Disassemble 2548
Clean and Inspect 2549
Assemble and Install 2549
Torque Specifications 2550
524223765 1800YRM1135 (09 2018) UK EN 2555
General 2559
Dry Brake System 2559
Wet Brake System 2559
Service Brakes Repair (Dry Brake) 2559
Remove and Disassemble 2560
Clean 2568
Inspect 2568
Assemble and Install 2569
Adjust 2576
Inching Overlap Adjustment 2576
Parking Brake Repair 2577
Remove and Disassemble 2577
Assemble and Install 2580
Adjust 2580
Master Cylinder Repair 2581
Remove (Dry Brake) 2581
Disassemble (Dry Brake) 2582
Clean and Inspect (Dry Brake) 2584
Assemble (Dry Brake) 2584
Bench Bleed Master Cylinder (Dry Brake) 2584
Install and Adjust (Dry Brake) 2584
Remove (Wet Brake) 2585
Disassemble (Wet Brake) 2587
Clean and Inspect (Wet Brake) 2588
Assemble (Wet Brake) 2589
Install and Adjust (Wet Brake) 2589
Service Brakes Adjustment (Dry Brake) 2590
Brake System Air Removal 2590
Using Pressure Bleed System 2590
Using Brake Pedal Pressure 2591
Brake Pedal Adjustment 2591
Free Pedal Adjustment 2592
Torque Specifications 2594
524223766 1900YRM1136 (11 2017) UK EN 2597
General 2601
Hydraulic Gear Pump Assembly 2602
Variable Displacement Pump Assembly 2603
Single Gear Pump Assembly Repair 2603
Remove 2603
Disassemble 2610
Clean 2610
Inspect 2612
Assemble 2612
Install 2612
Tandem Gear Pump Assembly 2616
Remove 2617
Disassemble 2619
Clean 2621
Inspect 2621
Assemble 2621
Install 2622
Gear Pump Specifications 2622
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2628
Remove 2628
Disassemble 2638
Clean 2641
Inspect 2641
Assemble 2641
Install 2642
63 0 cc/rev – Variable Displacement Pump Repair 2645
Remove 2645
Disassemble 2648
Clean 2648
Inspect 2648
Assemble 2650
Install 2650
Variable Displacement Pump Checks and Adjustments (Single Pump) 2652
Margin Pressure Check 2652
Flow Compensator Adjustment 2653
Pressure Compensator Adjustment 2653
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2654
Variable Displacement Pump Specifications 2657
Torque Specifications 2658
Hydraulic Gear Pump 2659
Variable Displacement Pump 2660
Special Tools 2660
524223767 2000YRM1137 (01 2017) UK EN 2665
General 2671
Electro-Hydraulic Main Control Valve 2672
Description 2672
Remove 2680
Electro-Hydraulic Control Valve Sections 2685
General 2685
Outlet Control Valve Section 2685
Remove 2685
Disassemble 2686
Clean 2688
Inspect 2688
Assemble 2688
Install 2689
Auxiliary Control Valve Sections 2689
Remove 2689
Disassemble 2696
Clean 2697
Inspect 2698
Assemble 2698
Install 2700
Tilt Control Valve Section 2701
Remove 2701
Disassemble 2701
Clean 2707
Inspect 2707
Assemble 2707
Install 2708
Lift/Lower Control Valve Section 2709
Remove 2709
Disassemble 2709
Clean 2718
Inspect 2718
Assemble 2718
Install 2719
Mid-Inlet Section 2719
Remove 2719
Clean 2720
Inspect 2720
Install 2720
Install 2720
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2725
Lift Pilot Pin 2725
Lower Pilot Pin 2729
Abnormal/Erroneous EHPV Adjustment 2731
Manual Main Control Valve 2732
Description 2732
Remove 2736
OPS Solenoid Assembly 2744
General 2744
Remove 2745
Clean and Inspect 2748
Install 2748
Manual Control Valve Sections 2749
General 2749
Outlet Control Valve Section 2749
Remove 2749
Disassemble 2749
Clean 2752
Inspect 2752
Assemble 2752
Install 2753
Auxiliary Control Valve Sections 2753
Remove 2753
Disassemble 2753
Clean 2756
Inspect 2756
Assemble 2756
Install 2757
Lift/Tilt Control Valve Section 2757
Remove 2757
Disassemble 2757
Clean 2764
Inspect 2764
Assemble 2765
Install 2766
Mid-Inlet Section 2767
Remove 2767
Clean 2767
Inspect 2767
Install 2767
Install 2768
Pressure Relief Valve Check and Adjustment 2774
Primary Relief Valve 2775
Secondary Relief Valve 2779
Steering Control Unit Repair 2786
Steering Control Unit, Remove 2786
Steering Control Unit, Disassemble 2790
Steering Control Unit, Clean 2792
Steering Control Unit, Inspect 2792
Steering Control Unit, Assemble 2792
Relief Valve, Disassemble 2793
Relief Valve, Clean 2793
Relief Valve, Inspect 2794
Relief Valve, Assemble 2794
Steering Control Unit, Install 2794
524223768 2100YRM1139 (02 2014) UK EN 2799
524223769 2200YRM1128 (01 2023) US EN 2847
Series Code / Model Designation Reference Table 2855
General 2857
Deutsch Crimping Tool 2858
How to Strip a Wire for Use With Deutsch Crimping Tool 2858
How to Crimp With the Deutsch Crimping Tool 2859
Calibration Test for the Deutsch Crimping Tool 2861
Deutsch Connectors 2863
DT, DTM, and DTP Series Connectors 2863
HD Series Connectors 2906
Metri-Pack Connectors 2928
Remove and Install 2928
Micro-Pack Connectors 2931
Weather-Pack Connectors 2932
AMPSEAL Crimping Tools 2934
AMP Hand Crimping Tool With Certi-Crimp 2934
Description 2934
Stripping Wire for Use with AMP Hand Crimping Tool 2935
Insulation Crimp Adjustment 2936
Maintenance and Inspection for AMP Hand Crimping Tool 2936
AMP Hand Crimping Tool 2936
Crimp Height Inspection 2936
How to use AMP Hand Crimping Tool 2937
AMP Pro-Crimper II Tool 2937
Description 2937
Remove and Install Die Set and Locator Assembly 2938
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2938
Contact Support Adjustment 2939
Crimp Height Adjustment 2940
Maintenance and Inspection Procedures 2940
PRO-CRIMPER II Tool 2940
Crimp Height Inspection 2940
How to Use AMP PRO-CRIMPER II Tool 2941
AMPSEAL Connector Assemblies 2942
Description for Plug Connector Assembly 2942
Seal Plug 2943
Contact Crimping 2943
Description for Plug Connector and Header Assembly 2948
Voltage Reading 2951
Seal Plug 2951
Contact Crimping 2951
AMP Superseal 1 5 Crimping Tools 2958
Mini Mic Receptacle and Tab Contacts 2958
Description 2958
Crimping Conditions and Measurements 2958
Insertion of Rubber Seal on Cable 2960
AMP Hand Application Tool 2965
Description 2965
Maintenance and Inspection 2965
Crimp Height Inspection 2965
Crimp Height Adjustment 2966
How to Use AMP Hand Application Tool 2966
AMP Pro-Crimper II Tool 2967
Description 2967
Remove and Install Die Set and Locator Assembly 2967
Adjustments 2968
Contact Support 2968
Crimp Height 2969
Inspections and Maintenance 2970
Crimp Height Inspection 2970
Visual Inspection 2970
Maintenance 2971
How to Use Pro-Crimper II Tool 2971
AMP Superseal 1 5 Connector Assemblies 2972
Description 2972
Repair and Maintenance 2979
Panel Mount Option 2979
AMP Fastin-Faston Hand Tools 2980
Description – AMP Double Action Hand Tool 2980
Maintenance and Inspection Procedures 2980
Daily Maintenance 2980
Periodic Tool Inspection 2981
Lubrication 2981
Visual Inspection 2981
Crimp Height Inspection 2981
Certi-Crimp Ratchet Inspection 2982
How to Use AMP Double Action Hand Tool 2983
Description – AMP Extraction Tool 2984
Maintenance and Inspection 2985
How to Use AMP Extraction Tool 2985
AMP Fastin-Faston Receptacles and Housings 2987
Description 2987
Wire Repair 2995
Wire Splicing Requirements 2995
Deutsch Jiffy Splice 2996
Twisted/Shielded Cable and Leads Repair 3002
Special Tools 3004
524223769 2200YRM1128 (07 2020) UK EN 3013
Series Code / Model Designation Reference Table 3019
General 3022
Deutsch Crimping Tool 3022
How to Strip a Wire for Use With Deutsch Crimping Tool 3022
How to Crimp With the Deutsch Crimping Tool 3023
Calibration Test for the Deutsch Crimping Tool 3025
Deutsch Connectors 3027
DT, DTM, and DTP Series Connectors 3027
HD Series Connectors 3069
Metri-Pack Connectors 3092
Remove and Install 3092
Micro-Pack Connectors 3094
Weather-Pack Connectors 3095
AMPSEAL Crimping Tools 3097
AMP Hand Crimping Tool With Certi-Crimp 3097
Description 3097
Stripping Wire for Use with AMP Hand Crimping Tool 3097
Insulation Crimp Adjustment 3098
Maintenance and Inspection for AMP Hand Crimping Tool 3098
AMP Hand Crimping Tool 3098
Crimp Height Inspection 3098
How to use AMP Hand Crimping Tool 3099
AMP Pro-Crimper II Tool 3099
Description 3099
Remove and Install Die Set and Locator Assembly 3100
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 3101
Contact Support Adjustment 3101
Crimp Height Adjustment 3102
Maintenance and Inspection Procedures 3102
PRO-CRIMPER II Tool 3102
Crimp Height Inspection 3102
How to Use AMP PRO-CRIMPER II Tool 3103
AMPSEAL Connector Assemblies 3104
Description for Plug Connector Assembly 3104
Seal Plug 3105
Contact Crimping 3105
Description for Plug Connector and Header Assembly 3110
Voltage Reading 3112
Seal Plug 3112
Contact Crimping 3112
AMP Superseal 1 5 Crimping Tools 3119
Mini Mic Receptacle and Tab Contacts 3119
Description 3119
Crimping Conditions and Measurements 3119
Insertion of Rubber Seal on Cable 3121
AMP Hand Application Tool 3126
Description 3126
Maintenance and Inspection 3126
Crimp Height Inspection 3126
Crimp Height Adjustment 3127
How to Use AMP Hand Application Tool 3127
AMP Pro-Crimper II Tool 3128
Description 3128
Remove and Install Die Set and Locator Assembly 3129
Adjustments 3129
Contact Support 3129
Crimp Height 3130
Inspections and Maintenance 3131
Crimp Height Inspection 3131
Visual Inspection 3131
Maintenance 3132
How to Use Pro-Crimper II Tool 3132
AMP Superseal 1 5 Connector Assemblies 3133
Description 3133
Repair and Maintenance 3140
Panel Mount Option 3140
AMP Fastin-Faston Hand Tools 3141
Description – AMP Double Action Hand Tool 3141
Maintenance and Inspection Procedures 3141
Daily Maintenance 3141
Periodic Tool Inspection 3142
Lubrication 3142
Visual Inspection 3142
Crimp Height Inspection 3142
Certi-Crimp Ratchet Inspection 3143
How to Use AMP Double Action Hand Tool 3144
Description – AMP Extraction Tool 3145
Maintenance and Inspection 3145
How to Use AMP Extraction Tool 3146
AMP Fastin-Faston Receptacles and Housings 3147
Description 3147
Wire Repair 3154
Wire Splicing Requirements 3154
Deutsch Jiffy Splice 3155
Twisted/Shielded Cable and Leads Repair 3160
Special Tools 3163
524223770 2200YRM1130 (03 2020) UK EN 3171
General 3175
Description 3175
Dash Display Menu Access 3175
Menu Navigation 3176
Standard Display 3176
Main Menu 3176
Passwords Menu 3177
Password Administration 3177
Add Password 3177
Delete Password 3178
Edit Password 3178
Other Password Functions 3179
Operator Passwords – Enable/Disable 3179
Password Time-Out Delay 3179
Passwords – Number Wrong to Disable 3180
Lockout Reset Password 3180
View Password Log 3181
View Versions 3182
VSM Versions 3182
Dash Display Versions 3183
Engine Controller Version 3184
Transmission (Xmsn) Controller Version 3185
Truck Serial Number 3186
Diagnostics 3187
View Fault Log 3187
Set Travel and Braking 3188
Speed Limit 3188
Acceleration Rate 3189
Auto-Deceleration Rate 3189
Set Power Reversal Rate 3190
Set Inching/Brake Overlap 3191
Setup Display Menu 3192
Set Operator Language 3192
Set Units 3193
Set Time Format (12/24 Hour) 3193
Set Daylight Saving Time 3193
Set Time 3196
Set Date Format 3197
Set Date 3197
Setup Hydraulics 3198
Return to Set Tilt Delay/On/Off 3198
Setup General Items 3199
Light Shutdown Time-Out 3199
Impact Sensor – Enable/Disable 3200
Impact Sensor – Soft Impact Settings 3201
Impact Sensor – Hard Impact Settings 3202
Adjust Impact Sensor Settings 3202
Initial Adjustment of Soft and Hard Impact Settings 3204
Readjustment of Soft and Hard Impact Settings 3204
Impact Sensor – Impact Alarm/Shutdown Reset 3205
Impact Sensor – Alarm Time Duration and Deactivation 3206
Impact Sensor – View Impact Event Log 3207
Engine Mode Indicator 3208
Generation 1 (ECO-eLo ONLY) 3208
Generation 2 3209
Operator Checklist 3210
Operator Checklist Off-On Mode 3210
Edit Operator Checklist 3210
Set Operator Checklist Expiration 3211
View Checklist Log 3211
Clear Operator Checklist Log 3212
Clear Operator Checklist Fault 3212
Calibrations 3213
Set Tilt Stop Point 3213
Calibrate Loaded Weight 3213
524223771 2200YRM1131 (03 2020) UK EN 3215
Series Code / Model Designation Reference Table 3221
General 3223
Description 3223
Dash Display Menu Access 3223
Menu Navigation 3224
Main Menu 3224
Passwords 3225
Adding Passwords 3225
Hourmeters 3227
View Versions 3228
VSM Versions 3228
Dash Display Versions 3229
Engine Controller Version 3230
Transmission (Xmsn) Controller Version 3231
Truck Serial Number 3232
Truck Configuration 3233
Diagnostics 3234
Clear Fault Log 3234
View Fault Log 3235
No-Run Data Display 3236
Engine Accelerator and Throttle Data Display 3236
Engine Speeds and Governor Data Display 3237
Engine Fuel and Emissions Data Display 3238
Engine General Data Display 3240
XMSN/Brake Data Display 3241
Hydraulic Data Display 3244
General Truck Data Display 3246
Set Travel and Braking 3247
Speed Limit 3247
Acceleration Rate 3248
Auto-Deceleration Rate 3249
Set Power Reversal Rate 3249
Set Inching/Brake Overlap 3250
Setup Hydraulics 3250
Lift Maximum Speed 3251
Lower Maximum Speed 3251
Tilt Maximum Speed 3252
Auxiliary Function One, Direction A, Maximum Speed 3254
Auxiliary Function One, Direction B, Maximum Speed 3256
Auxiliary Function Two, Direction A, Maximum Speed 3256
Auxiliary Function Two, Direction B, Maximum Speed 3257
Auxiliary Function Three, Direction A, Maximum Speed 3258
Auxiliary Function Three, Direction B, Maximum Speed 3258
Lift/Lower Ramp Rate 3259
Hydraulic Auxiliary Ramp Rate 3259
Return to Set Tilt Delay/On/Off 3260
Hydraulic Input Device 3261
Auxiliary Solenoid 3261
Dual Function 3262
Setup Display 3263
Set Service Language 3263
Setup General Items 3263
Motion Alarm Activation Type 3264
Light Shutdown Time-Out 3265
Restore Default Settings 3265
Restore Engine Controller Default Calibration 3266
Impact Sensor – Enable/Disable 3266
Impact Sensor – Soft Impact Settings 3267
Impact Sensor – Hard Impact Settings 3268
Adjust Impact Sensor Settings 3269
Initial Adjustment of Soft and Hard Impact Settings 3271
Readjustment of Soft and Hard Impact Settings 3271
Impact Sensor – Impact Alarm/Shutdown Reset 3272
Impact Sensor – Alarm Time Duration and Deactivation 3273
Impact Sensor – View Impact Event Log 3274
Engine Mode Indicator 3274
Generation 1 (ECO-eLo ONLY) 3274
Generation 2 3275
Diesel Particulate Filter (DPF) Display 3276
General Description 3276
Passive Regeneration Only 3276
Regeneration Level 0 3276
Auto/Active Regeneration Inhibited 3277
Auto/Active Regeneration 3277
Regeneration Level 1 3277
Parked Regeneration Request 3278
Regeneration Level 2 3278
Warning Level 3278
Regeneration Level 3 3278
Service Level 3279
Regeneration Level 4 3279
Display, Diesel Particulate Filter (DPF), Revised 3279
Operator Interface 3279
Refer to Operator Manual 3279
CAN Communication Lost 3280
Passive Regeneration Only 3280
Regeneration Level 0 3280
Auto/Active Regeneration Inhibited 3280
Auto/Active Regeneration 3281
Regeneration Level 1 3281
Idle-up Auto/Active Regeneration 3281
Parked Regeneration Request 3281
Regeneration Level 2 3281
Warning Level 3283
Regeneration Level 3 3283
Service Level 3283
Regeneration Level 4 3283
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3283
Display, Diesel Particulate Filter (DPF), Stage V Engine 3283
Operator Interface 3284
Refer to Operator Manual 3284
CAN Communication Lost 3284
Passive Regeneration Only 3284
Regeneration Level 0 3284
Auto/Active Regeneration Inhibited 3285
Auto/Active Regeneration 3285
Regeneration Level 1 3285
Idle-up Auto/Active Regeneration 3286
Parked Regeneration Request 3286
Regeneration Level 2 3286
Warning Level 3287
Regeneration Level 3 3287
Service Level 3288
Regeneration Level 4 3288
Stage V Content 3288
Emissions System Malfunction 3288
Ash Load 3288
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3289
Operator Interface 3289
Refer to Operator Manual 3289
CAN Communication Lost 3290
Passive Regeneration Only 3290
Regeneration Level 0 3290
Auto/Active Regeneration Inhibited 3290
Auto/Active Regeneration 3291
Regeneration Level 1 3291
Idle-up Auto/Active Regeneration 3291
Parked Regeneration Request 3291
Regeneration Level 2 3291
Warning Level 3293
Regeneration Level 3 3293
Service Level 3293
Regeneration Level 4 3293
Calibrations 3294
Calibrate Transmission Valve 3296
Set Tilt Stop Point 3296
Calibrate Loaded Weight 3296
Calibrate Travel Speed Sensor 3297
Calibrate Mazda LP and Gas Accelerator Pedal 3297
524223772 2200YRM1142 (01 2020) UK EN 3299
General 3309
Display Switch Cluster 3312
Remove 3312
Install 3315
Direction Control and Turn Signal Levers 3315
Remove 3315
Install 3317
Key Switch 3317
Remove 3317
Install 3318
Display Switch Cluster Panel Bezel and Overlay 3318
Remove 3318
Install 3318
Steering Column Repair 3318
Remove 3318
Disassemble 3321
Assemble 3321
Install 3321
Sensors and Switches 3322
General 3322
Dash and Kick Panel, Remove and Install 3322
Remove 3322
Install 3323
Accelerator Pedal Position Sensor 3324
Remove 3324
Install 3327
Brake Fluid Level Switch 3328
Remove 3328
Install 3330
Service Brake Pedal Position Sensor 3331
Remove 3331
Install 3334
Parking Brake Sensor 3335
Remove 3335
Install 3336
Service Brake Pressure Sensor 3337
Remove 3337
Install 3339
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3340
Remove 3340
Install 3340
Sensor Microswitch (Foot Directional Control Pedal) 3341
Remove 3341
Install 3344
Low Coolant Level Sensor 3345
Remove 3345
Install 3348
Fuel Level Sensor, Gas and Diesel Engines Only 3349
Remove 3349
Install 3350
Armrest Switch 3350
Remove 3350
Install 3352
Seat Sensor (Operator Presence System) 3352
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3352
Remove 3352
Install 3353
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3353
Remove 3353
Install 3354
Full Suspension Seats; All Lift Truck Models 3354
Remove 3354
Install 3354
Hood Shut Off Switch 3354
Remove 3354
Install 3357
Remote Key Switch 3358
Remove 3358
Install 3358
Hydraulic Filter Pressure Switch 3359
Remove 3359
Install 3361
Transmission Speed Sensor 3361
Remove 3361
Install 3364
Transmission Pressure Sensors 3365
Remove 3365
Install 3367
Transmission Temperature Sensor 3368
Remove 3368
Install 3370
Engine Speed Sensor 3372
Remove 3372
Install 3372
Intermediate Speed Sensor 3373
Remove 3373
Install 3373
Return to Set Tilt (Tilt Angle) Sensor 3373
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3373
Remove 3373
Install 3374
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3375
Remove 3375
Install 3376
Rear Horn Button Switch 3376
Remove 3376
Install 3377
Impact Sensor 3378
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3378
Remove 3378
Install 3381
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3381
Remove 3381
Install 3382
Load Weight Sensor 3383
Remove 3383
Install 3384
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3385
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3385
Crankshaft Position (CKP) Sensor 3385
Camshaft Position (CMP) Sensor 3385
Oil Pressure Sensor 3385
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3385
Engine Coolant Temperature (ECT) Sensor 3386
Air Flow Restriction Switch 3386
Remove for GM 2 4L Gas and LPG Trucks 3386
Install for GM 2 4L Gas and LPG Trucks 3386
Oxygen Sensor 3387
Remove 3387
Install 3390
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3391
Crankshaft Position (CKP) Sensor 3391
Camshaft Position (CMP) Sensor 3391
Oil Pressure Sensor 3391
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3391
Engine Coolant Temperature (ECT) Sensor 3391
Air Flow Restriction Switch 3391
Oxygen Sensor 3391
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3391
Low LPG Pressure Switch 3391
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3392
Air Filter Restriction Switch 3392
Remove 3392
Install 3392
Oil Pressure Sensor 3392
Remove 3392
Install 3392
Engine Speed Sensor 3392
Remove 3392
Install 3392
Engine Coolant Temperature (ECT) Sensor 3392
Remove 3392
Install 3392
Throttle Position Sensor (TPS) 3395
Remove 3395
Install 3396
Fuel/Water Separator Sensor 3396
Remove 3396
Install 3396
Glow Plug Relay 3397
Remove 3397
Install 3399
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3399
Air Filter Restriction Switch 3399
Remove 3399
Install 3399
Engine Oil Pressure Sensor 3404
Remove 3404
Install 3404
Engine Speed Sensor 3404
Remove 3404
Install 3405
Engine Coolant Temperature (ECT) Sensor 3405
Remove 3405
Install 3406
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3407
Remove 3407
Install 3407
Fuel/Water Separator Sensor 3408
Remove 3408
Install 3408
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3409
Intake Air Temperature Sensor 3409
Remove 3409
Install 3410
Intake Air Pressure Sensor 3410
Remove 3410
Install 3410
Air Inlet Heater 3410
Remove 3410
Install 3411
Engine Oil Pressure Sensor 3411
Remove 3411
Install 3411
Engine Coolant Temperature (ECT) Sensor 3411
Remove 3411
Install 3411
Crankshaft Position Sensor 3412
Remove 3412
Install 3412
Adjust Shim Procedure 3413
Camshaft Position Sensor 3414
Remove 3414
Install 3414
Air Flow Restriction Sensor 3415
Remove 3415
Install 3415
Fuel/Water Separator 3415
Remove 3415
Install 3416
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3416
Intake Air Temperature Sensor 3420
Remove 3420
Install 3421
Boost Sensor 3421
Remove 3421
Install 3422
Throttle Valve Assembly and Air Intake Heater 3422
Remove 3422
Install 3422
Engine Coolant Temperature (ECT) Sensor 3423
Remove 3423
Install 3423
Engine Oil Pressure Sensor 3423
Remove 3423
Install 3424
Crankshaft Position Sensor 3424
Remove 3424
Install 3424
Adjust Shim Procedure 3425
Camshaft Position Sensor 3426
Remove 3426
Install 3427
Differential Pressure Sensor 3427
Remove 3427
Install 3427
Mass Air Flow Sensor 3428
Remove 3428
Install 3429
Fuel/Water Separator 3429
Remove 3429
Install 3430
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3430
Engine Coolant Temperature (ECT) Sensor 3431
Remove 3431
Install 3431
Throttle Position Sensor 3432
Engine Oil Pressure Sensor 3432
Remove 3432
Install 3432
Engine Speed Sensor 3432
Remove 3432
Install 3432
Fuel Shut Off Solenoid 3432
Remove 3432
Install 3432
Vehicle System Manager (VSM) 3433
General 3433
VSM Replacement 3433
Remove 3433
Install 3435
Programming a New VSM and/or Display Switch Cluster 3435
General 3435
PC Service Tool Software 3436
Data Transferring 3436
New VSM 3436
New (Blank) Display Switch Cluster 3436
Used (Non-Blank) Display Switch Cluster 3436
Power Distribution Module (PDM) and Component Parts 3438
Remove 3438
PDM as a Unit 3438
Install 3442
PDM as a Unit 3442
Remove and Install 3443
PDM Component Parts 3443
Transmission Control Unit 3443
Remove 3443
Install 3447
Battery 3449
Remove 3449
Install 3449
Lights 3450
Work Lights (Front and Rear) 3450
Remove 3450
Install 3450
Strobe Light 3451
Remove 3451
Install 3451
LED Tail, Backup, and Brake Lights 3452
Remove 3452
Install 3453
Front Marker/Turn Signal Lights 3454
Replacing Whole Front Marker/Turn Signal Light Assembly 3454
Remove 3454
Install 3454
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3455
Remove 3455
Install 3455
Diesel Particulate Filter (DPF) Display 3455
Remove 3455
Clean and Inspect 3456
Install 3456
Electronic-Hydraulic Controls – Generation 1 3457
E-Hydraulic Controls – Test 3457
Mini-Levers 3457
Full Stroke Test 3457
Function Returns to Neutral Test 3457
Push Button Switch 3457
General 3458
Mini-Lever Replacement 3458
Remove 3458
Clean and Inspect 3459
Install 3459
Push Button Switch Replacement 3460
Remove 3460
Install 3462
Mini-Lever Module (MLM) 3462
Remove 3462
Install 3462
Joystick 3463
Remove and Disassemble 3463
Inspect 3463
Assemble and Install 3463
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3464
General 3464
Mini-levers, Remove and Install 3464
Armrest Assembly 3465
Remove 3465
Install 3468
Horn Button 3468
Remove 3468
Install 3468
Direction Control Switch 3469
Remove 3469
Install 3469
push (override) buttons and Toggle Switch 3469
Remove 3470
Install 3471
Joystick 3472
Remove and Disassemble 3472
Inspect 3472
Assemble and Install 3472
Joystick Armrest Slider Assembly 3473
Remove 3473
Install 3474
Electronic-Hydraulic Controls, After January, 2020 3474
E-Hydraulic Controls – TEST 3474
Mini-Levers 3474
Full Stroke Test 3474
Function Returns to Neutral Test 3474
Push (Override) Button 3475
General 3475
Mini-levers, Remove and Install 3475
Armrest Assembly 3476
Remove 3476
Install 3479
Horn Button 3479
Remove 3479
Install 3479
Direction Control Switch 3479
Remove 3479
Install 3480
Push (Override) buttons and Toggle Switch 3480
Remove 3481
Install 3483
Special Tools 3484
524223773 2200YRM1143 (10 2005) UK EN 3487
toc 3487
Electrical System 3487
Safety Precautions Maintenance and Repair 3488
Ignition System 3491
General 3491
Ignition Timing Adjustment, Gasoline and LPG 3491
Spark Plugs Check 3491
Spark Plug Wires Check 3491
Distributor Repair 3494
Remove 3494
Disassemble 3495
Inspect 3495
Assemble 3496
Install 3496
Igniter 3497
Remove 3497
Test 3497
Install 3497
Camshaft Position (CMP) Sensor 3498
Voltage Check 3498
Ignition Coil Check 3499
Primary Coil Winding 3499
Secondary Coil Winding 3499
Starter Repair 3500
General 3500
Remove 3500
No-Load Test 3501
Magnetic Switch Test 3501
Pull-Out Test 3501
Holding Coil Test 3502
Return Test 3502
Pinion Movement Inspection 3502
Install 3502
Alternator Repair 3503
General 3503
Charging System Inspection 3503
Output Current Check 3504
No-Load Adjusted Voltage Check 3504
Remove 3505
Inspect 3505
Rectifier Check 3505
Install 3506
tables 3487
Table 1 Spark Plug Wire 3491
Table 2 Starter Specifications 3500
Table 3 Problem Diagnosis Chart 3501
Table 4 Specifications 3504
Table 5 Rectifier Check Table 3505
524223776 4000YRM1148 (09 2015) UK EN 3509
General 3513
Safety Procedures When Working Near Mast 3514
Fork Replacement 3516
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3516
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3518
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3519
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3519
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3520
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3521
Carriages Repair 3522
Standard Carriage 3522
Remove 3522
Repair 3523
Install 3523
Standard Carriage, Remove 3524
Hang-On Sideshift Carriage, Remove 3525
Standard Carriage and Hang-On Sideshift Carriage, Repair 3526
Standard Carriage, Install 3527
Hang-On Sideshift Carriage, Install 3527
Integral Sideshift Carriage 3528
Remove 3528
Clean and Inspect 3531
Repair 3532
Install 3532
Fork Positioner 3533
Remove 3533
Clean and Inspect 3538
Disassemble and Assemble 3538
Install 3538
Fork Positioner Hydraulic Hose Adjustment 3539
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3541
Connecting Attachment Hydraulic Quick Disconnect Hoses 3541
Mast Repair 3542
Mast, Remove 3542
Two-Stage LFL and Two-Stage FFL Masts 3545
Disassemble 3545
Clean and Inspect 3555
Three-Stage FFL Mast 3556
Disassemble 3556
Clean and Inspect 3564
Two-Stage LFL and Two-Stage FFL Mast 3566
Assemble 3566
Three-Stage FFL Mast 3569
Assemble 3569
Four-Stage FFL Mast – Manufactured Before July, 2009 3571
Disassemble 3571
Clean and Inspect 3576
Assemble 3578
Four-Stage FFL Mast – Manufactured After July, 2009 3579
Disassemble 3579
Clean and Inspect 3586
Assemble 3589
Mast, Install 3590
Header Hose Arrangement 3593
Two-Stage LFL 3593
Two-Stage FFL 3601
Three-Stage FFL 3616
Standard 3616
Optional Equipment Lift Truck GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3633
Four-Stage FFL Mast – Manufactured Before July, 2009 3641
Four-Stage FFL Mast – Manufactured After July, 2009 3650
Adjustment 3657
Lift Chains Adjustment 3657
Carriage Adjustments 3660
Mast Adjustments 3660
Load Roller Adjustment 3660
Mast Side Kicking Adjustment 3663
524223778 8000YRM1151 (10 2016) UK EN 3667
Lift Truck Lifting Capacity 3671
Counterweight Weights 3671
Tire Sizes 3671
Capacities 3672
Electrical System 3677
Transmission Oil Pressures 3678
Hydraulic System Relief Pressures 3682
Steering System 3683
Stall Speeds (in RPM ±100 rpm) 3684
Mazda FE (Except 2007 Emission Compliant Engines) 3684
Mazda FE (2007 Emission Compliant Engines Only) 3684
Mazda F2 (Except 2007 Emission Compliant Engines) 3684
Mazda F2 (2007 Emission Compliant Engines Only) 3684
GM 2 4L 3685
Yanmar 2 6L 3685
Yanmar 3 3L 3685
Mast Speeds 3685
Tilt Angles 3688
Front End Equipment – Mast Creep 3689
Mast Creep 3689
Engine Specifications 3689
Torque Specifications 3691
Frame 3691
Mast 3691
Steering System, Cushioned Tire Trucks 3691
Steering System, Pneumatic Tire Trucks 3692
Drive Axle (Dry Brake) 3692
Drive Axle (Wet Brake) 3692
Transmission – Iron Housing 3693
Transmission – Aluminum Housing 3693
Engine – Mazda FE and F2 3694
Engine – GM 2 4L 3695
Engine – Yanmar 2 6L and 3 3L Diesel 3696
524223779 8000YRM1152 (03 2020) UK EN 3701
General Information About Diagrams and Schematics 3705
Symbol Definitions 3705
Diagrams Manual Applications 3706
Diagrams and Schematics 3708
524223780 8000YRM1134 (03 2020) UK EN 3771
Series Code / Model Designation Reference Table 3777
Description 3779
Proc_Cal_001: Service Password Entry 3781
When to Perform 3781
Why Perform 3781
How to Perform 3781
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3782
When to Perform 3782
Calibration Order 3782
Why Perform 3782
How to Perform 3783
Proc_Cal_003: Save and Exit 3784
When to Perform 3784
Why Perform 3784
How to Perform 3784
Proc_Cal_004: Lift Valve Output Threshold 3785
When to Perform 3785
Calibration Order 3785
Why Perform 3785
How to Perform 3786
Proc_Cal_005: Lower Valve Output Threshold 3788
When to Perform 3788
Calibration Order 3788
Why Perform 3788
How to Perform 3788
Proc_Cal_006: Tilt Back Valve Output Threshold 3791
When to Perform 3791
Calibration Order 3791
Why Perform 3791
How to Perform 3791
Proc_Cal_007: Tilt Forward Valve Output Threshold 3794
When to Perform 3794
Calibration Order 3794
Why Perform 3794
How to Perform 3794
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3797
When to Perform 3797
Calibration Order 3797
Why Perform 3797
How to Perform 3797
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3800
When to Perform 3800
Calibration Order 3800
Why Perform 3800
How to Perform 3800
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3803
When to Perform 3803
Calibration Order 3803
Why Perform 3803
How to Perform 3803
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3806
When to Perform 3806
Calibration Order 3806
Why Perform 3806
How to Perform 3806
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3809
When to Perform 3809
Calibration Order 3809
Why Perform 3809
How to Perform 3809
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3812
When to Perform 3812
Calibration Order 3812
Why Perform 3812
How to Perform 3812
Proc_Cal_014: Load Weight Zero Point 3816
When to Perform 3816
Calibration Order 3816
Why Perform 3816
How to Perform 3816
Proc_Cal_015: Loaded Weight Calibration 3818
When to Perform 3818
Calibration Order 3818
Why Perform 3818
How to Perform 3818
Proc_Cal_016: Transmission Valve Calibration 3821
Applicable System/Option 3821
When to Perform 3821
Calibration Order 3821
Why Perform 3821
How to Perform 3821
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3823
Applicable System/Option 3823
When to Perform 3823
Calibration Order 3823
Why Perform 3823
How to Perform 3823
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3825
Applicable System/Option 3825
When to Perform 3825
Calibration Order 3825
Why Perform 3825
How to Perform 3826
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3827
Required Tools 3827
When to Perform 3827
Calibration Order 3827
Why Perform 3828
How to Perform 3828
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3829
When to Perform 3829
Why Perform 3829
How to Perform 3829
Proc_Cal_026: Travel Speed Calibration 3831
When to Perform 3831
Calibration Order 3831
Why Perform 3831
How to Perform 3831
524223780 8000YRM1134 (05 2022) US EN 3835
Series Code / Model Designation Reference Table 3841
Description 3844
Proc_Cal_001: Service Password Entry 3846
When to Perform 3846
Why Perform 3846
How to Perform 3846
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3847
When to Perform 3847
Calibration Order 3847
Why Perform 3847
How to Perform 3847
Proc_Cal_003: Save and Exit 3849
When to Perform 3849
Why Perform 3849
How to Perform 3849
Proc_Cal_004: Lift Valve Output Threshold 3850
When to Perform 3850
Calibration Order 3850
Why Perform 3850
How to Perform 3850
Proc_Cal_005: Lower Valve Output Threshold 3853
When to Perform 3853
Calibration Order 3853
Why Perform 3853
How to Perform 3853
Proc_Cal_006: Tilt Back Valve Output Threshold 3856
When to Perform 3856
Calibration Order 3856
Why Perform 3856
How to Perform 3856
Proc_Cal_007: Tilt Forward Valve Output Threshold 3859
When to Perform 3859
Calibration Order 3859
Why Perform 3859
How to Perform 3859
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3862
When to Perform 3862
Calibration Order 3862
Why Perform 3862
How to Perform 3862
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3865
When to Perform 3865
Calibration Order 3865
Why Perform 3865
How to Perform 3865
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3868
When to Perform 3868
Calibration Order 3868
Why Perform 3868
How to Perform 3868
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3871
When to Perform 3871
Calibration Order 3871
Why Perform 3871
How to Perform 3871
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3874
When to Perform 3874
Calibration Order 3874
Why Perform 3874
How to Perform 3874
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3877
When to Perform 3877
Calibration Order 3877
Why Perform 3877
How to Perform 3877
Proc_Cal_014: Load Weight Zero Point 3880
When to Perform 3880
Calibration Order 3880
Why Perform 3880
How to Perform 3880
Proc_Cal_015: Loaded Weight Calibration 3882
When to Perform 3882
Calibration Order 3882
Why Perform 3882
How to Perform 3882
Proc_Cal_016: Transmission Valve Calibration 3885
Applicable System/Option 3885
When to Perform 3885
Calibration Order 3885
Why Perform 3885
How to Perform 3885
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3887
Applicable System/Option 3887
When to Perform 3887
Calibration Order 3887
Why Perform 3887
How to Perform 3887
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3890
Applicable System/Option 3890
When to Perform 3890
Calibration Order 3890
Why Perform 3890
How to Perform 3890
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3893
Required Tools 3893
When to Perform 3893
Calibration Order 3893
Why Perform 3893
How to Perform 3893
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3895
When to Perform 3895
Why Perform 3895
How to Perform 3895
Proc_Cal_026: Travel Speed Calibration 3897
When to Perform 3897
Calibration Order 3897
Why Perform 3897
How to Perform 3897
524240453 0600YRM1205 (01 2017) UK EN 3901
General 3907
Engine Identification 3907
Major Engine Component Identification 3907
Location of Labels 3908
Engine Removal and Installation 3909
Cylinder Head Assembly Repair 3909
Glow Plugs 3912
Remove 3912
Install 3912
Valve Cover 3912
Remove 3912
Clean and Inspect 3913
Install 3913
Rocker Arm Assembly 3913
Remove 3913
Disassemble 3914
Clean and Inspect 3915
Push Rods 3915
Rocker Arm Assembly 3915
Assemble 3915
Install 3916
Valve Clearance Adjustments 3916
Cylinder Head Assembly 3917
Remove 3917
Disassemble 3922
Valves and Valve Springs, Remove 3922
Valve Guides, Remove 3922
Clean and Inspect 3923
Cylinder Head 3923
Valve Guides 3924
Valves 3924
Valve Sink 3924
Valve Seat 3925
Valve Springs 3925
Assemble 3926
Valve Guides, Install 3926
Valves and Valve Springs, Install 3926
Install 3927
Timing Gear Case and Timing Gears Repair 3928
Timing Gear Case Cover 3929
Remove 3929
Clean and Inspect 3929
Install 3930
Timing Gears 3930
Crankshaft Gear 3931
Remove 3931
Install 3931
Idler Gear 3931
Remove 3931
Inspect 3932
Install 3932
Camshaft Gear 3932
Remove 3932
Install 3933
Timing Gear Case 3933
Remove 3933
Clean and Inspect 3934
Install 3934
Drive Train, Camshaft, and Cylinder Block Repair 3935
Remove 3935
Disassemble 3936
Pistons and Connecting Rods 3936
Crankshaft 3936
Camshaft 3939
Clean and Inspect 3940
Cylinder Block 3940
Honing and Boring 3943
Pistons 3944
Piston Pin 3944
Connecting Rod 3945
Tappets 3945
Crankshaft 3946
Camshaft 3947
Camshaft Bushing 3948
Assemble 3948
Camshaft 3948
Crankshaft 3948
Pistons and Connecting Rods 3949
Install 3950
Lubrication System Repair 3951
Engine Oil and Oil Filter Change 3951
Oil Pan 3951
Remove 3951
Install 3952
Oil Suction Tube 3952
Remove 3952
Clean 3953
Install 3953
Oil Pump 3953
Remove 3953
Clean and Inspect 3954
Outer Rotor Outside Clearance 3954
Outer Rotor to Inner Rotor Tip Clearance 3955
Outer Rotor Side Clearance 3955
Rotor Shaft Clearance 3955
Install 3956
Fuel System Repair 3956
Fuel Injectors 3957
Remove 3957
Inspect 3958
Clean 3958
Test 3958
Install 3961
Electronic Throttle System 3961
Remove 3961
Install 3964
Inspect 3965
Adjust 3966
Manual Throttle System 3967
Fuel Injection Pump 3967
Remove 3967
Clean and Inspect 3971
Install 3971
Check/Adjust Fuel Injection Timing 3972
Cooling System Repair 3974
V-Belt 3974
Remove 3974
Inspect 3974
Install 3974
Adjust 3974
Water Pump 3976
4TNE92-NMHA, 4TNE92-NMHA/580090035, 4TNE92-SNMU, and 4TNE98-SNMU Engines 3976
Remove 3976
Install 3977
4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/580090036, and 4TNE98-BNMH Engines 3978
Remove 3978
Install 3979
Thermostat 3981
Remove 3981
Inspect 3982
Install 3982
Flywheel and Flywheel Housing 3982
Flywheel 3983
Remove 3983
Install 3984
Flywheel Housing 3984
Remove 3984
Install 3984
Electrical Equipment Repair 3986
Alternator 3986
Remove 3986
Bench Test 3988
Regulate Voltage Check 3988
No Load Test 3990
Output Test 3990
Install 3990
Starter 3991
Remove 3992
No Load Test 3992
Install 3993
Engine Specifications 3994
Engine Data 3994
Engine Tuning 4002
Cylinder Head 4002
Intake/Exhaust Valve and Guide 4003
Valve Spring 4003
Rocker Arm and Shaft 4003
Push Rod 4004
Gear Train and Camshaft 4004
Camshaft 4004
Idle Gear Shaft and Bushing 4004
Backlash of Each Gear 4005
Cylinder Block 4005
Crankshaft 4005
Thrust Bearing 4006
Piston 4006
Piston Ring 4006
Connecting Rod 4007
Rod Small End 4007
Tappet 4007
Oil Pump 4008
Engine Oil Pressure 4008
Outer Rotor Outside Clearance 4008
Outer Rotor Side Clearance 4008
Outer Rotor to Inner Rotor Tip Clearance 4008
Rotor Shaft Clearance 4008
Standard Torque Specifications 4009
Standard Torque Chart 4009
Special Torque Specifications 4010
Special Tools 4011
524240908 1400YRM1215 (02 2018) UK EN 4019
General 4023
Identification Plate 4023
Drive Axle Removal 4023
Reduction Gear Assembly 4029
Reduction Gear Assembly Repair 4029
Clean and Inspect 4039
Brake Repair 4053
Wet Disc Brake 4053
Clean and Inspect 4063
Wet Brake Noise Reduction 4077
General 4077
Adding Additive To Transmission 4077
Parking Brake Control Lever 4077
General 4077
Clean and Inspect 4080
Differential Repair 4084
Remove 4084
Clean and Inspect 4101
Gear Set, Tooth Contact Pattern Check 4121
Drive Axle Installation 4126
Special Tools 4131
Torque Specifications 4134
524240909 1400YRM1214 (11 2012) UK EN 4139
toc 4139
Drive Axle and Differential Assembly Repair 4139
Safety Precautions Maintenance and Repair 4140
General 4143
Drive Axle Repair 4143
Remove and Disassemble 4143
Clean and Inspect 4145
Assemble and Install 4145
Differential Repair 4148
Remove 4148
Differential Assembly From Center Section 4148
Drive Pinion, Pinion Gear, and Bearings From Center Section 4153
Disassemble 4158
Differential Assembly 4158
Drop Box Housing 4161
Center Section 4162
Clean and Inspect 4164
Assemble 4164
Center Section 4164
Drop Box Housing 4168
Differential Assembly 4169
Install 4173
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 4173
Drive Pinion, Pinion Gear, and Bearings Into Center Section 4175
Differential Assembly Into Center Section 4180
Ring Gear Backlash, Adjust 4186
Ring Gear, Runout Check 4187
Gear Set, Tooth Contact Pattern Check 4187
Torque Specifications 4190
tables 4139
Table 1 Pinion Variation Numbers Examples 4174
Table 2 Ring and Pinion Tooth Contact Adjustment 4187
Table 3 Correct Tooth Contact 4188
Table 4 Incorrect Tooth Contact 4189
524242683 8000YRM1150 (12 2017) UK EN 4193
General 4199
Serial Number Data 4199
How to Move Disabled Lift Truck 4199
How to Tow Lift Truck 4199
How to Put Lift Truck on Blocks 4200
How to Raise Drive Tires 4200
How to Raise Steering Tires 4201
How to Clean a Lift Truck 4202
Maintenance Schedule 4202
Maintenance Procedures Every 8 Hours or Daily 4220
How to Make Checks With Engine Stopped 4220
Tires and Wheels 4220
Safety Labels 4221
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4221
Operator Restraint System 4222
Emergency Locking Retractor (ELR) 4222
Adjust Seat – Full Suspension 4223
Hood and Seat Latches 4226
Engine Compartment 4226
Paper Application 4226
Fuel, Oil, and Coolant Leaks, Check 4227
Hydraulic Hoses 4227
Coolant Hoses 4227
Steering Column Gas Cylinder 4227
Transmission 4227
Hydraulic System Oil 4227
Engine Oil 4228
Air Filter 4230
Forks 4230
Remove 4230
Inspect 4230
Install 4230
Adjust 4231
How to Make Checks With Engine Running 4232
Indicator Lights, Horn, Fuses, and Relays 4232
Service Brakes 4234
Brake Fluid Level 4234
Operation, Check 4235
Parking Brake 4235
Engine Oil Pressure 4235
Cooling System 4236
Steering System 4237
Control Levers and Pedals 4237
Lift System, Operate 4237
First Service After First 100 Hours of Operation 4237
Mazda and GM Engine Oil and Oil Filter 4238
Yanmar Engine Oil and Oil Filter 4239
Maintenance Procedures Every 500 Hours or 1 Year 4239
Hydraulic System Oil 4239
Hydraulic Tank Breather 4240
Inspect 4240
Battery 4240
Engine Oil and Oil Filter, Mazda and Yanmar Engines 4241
Engine Oil and Oil Filter, GM 2 4L Engine 4242
Drive Belt 4242
Mazda Engines FE and F2 4242
Fan and Alternator Drive Belt 4242
Yanmar Diesel Engine 4243
Fan and Alternator Drive Belt 4243
GM 2 4L Engine 4244
Fan and Alternator Drive Belt 4244
Timing Belt, Checks and Inspection 4245
PCV Valve 4247
Clean Debris From Radiator Core 4247
Transmission Oil Level 4247
Wet Brake Planetary Housing Oil Level Check 4249
Forks 4250
Mast Lubrication 4250
Header Hose Checks 4254
Lift Chain Lubrication 4254
Tilt Cylinder Lubrication 4255
Master Brake Cylinder Rod End Pin Lubrication 4256
Manual Hydraulic Levers Lubrication 4256
Brake Fluid 4257
Drain Tar From LPG Regulator 4258
Tie Rod Lubrication 4259
Lift Truck Models GLP/GDP20-35VX 4259
Differential and Drive Axle Oil (Dry Brake) 4259
Maintenance Procedures Every 1000 Hours or 1 Year 4259
Valve Clearance, Check and Adjust 4260
Ignition System 4260
GM 2 4L Engine 4260
Mazda Engines FE and F2 4260
LPG Fuel Filter Element Replace, GM 2 4L Engine 4260
Remove 4260
Install 4260
LPG Vapor Fuel Filter Replace, Mazda Engines 4261
Fuel Filter Replacement, Yanmar Engine 4262
Priming the Fuel System (Yanmar) 4264
Lift Chains Wear Check 4264
Lift Chain Lubrication 4265
Integral Sideshift Carriage, Check Bearings 4265
Integral Sideshift Carriage, Check Lower Mounting Hooks 4266
Steering Axle 4266
Control Levers and Pedals 4266
Maintenance Procedures Every 2000 Hours or Annually 4266
Hydraulic System 4267
Hydraulic Filter, Replace 4267
Hydraulic Tank Breather, Replace 4268
Air Filter 4269
PCV Valve 4270
Oxygen Sensor 4271
LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4271
Remove and Replace 4271
LPG Regulator Fuel Filter, GM Engines 4271
Remove 4271
Install 4272
Timing Belt 4273
Mazda Engines 4273
GM 2 4L Engine 4273
LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Compliant Engines) 4273
LPG Fuel Injector, GM Engines 4273
Fuel Injector, Yanmar Engines 4273
Forks 4273
Integral Sideshift Carriage 4273
Bearings, Replace 4273
Transmission Oil and Filter (Dry Brake), Replace 4273
Iron Transmission Housing 4273
Aluminum Transmission Housing 4275
Remove 4275
Clean and Inspect 4278
Install 4278
Transmission Oil Change, Wet Brake Drive Axle 4279
Iron Transmission Housing 4279
Aluminum Transmission Housing 4281
Wet Brake Axle Center Section and Planetary Housing, Oil Change 4284
Brake Fluid (Master Cylinder), Change 4288
Brake Fluid (Dry Brake), Remove 4289
Steer Axle, Wheel Bearing Lubrication 4289
Service Brakes (Dry Brake) 4289
Differential (Dry Brake) 4290
Maintenance Procedures Every 4000 Hours or 2 Years 4290
Hydraulic Oil, Replace 4291
Cooling System 4291
Safety Procedures When Working Near Mast 4292
Hood Latch Check 4295
Lift Chain Adjustments 4296
Jump-Starting the Lift Truck 4298
Jump-Starting Using a Battery Charger 4298
Jump-Starting a Lift Truck Using Another Lift Truck 4298
Welding Repairs 4298
Overhead Guard Changes 4299
Wheel and Tire Replacement 4299
General 4300
Solid Rubber Tire, Change (GC/GLC Series) 4300
Remove and Install Tire on Wheel 4300
Pneumatic Tire With Tube, Repair 4301
Remove Wheels From Lift Truck 4301
Remove Tire From Wheel 4302
Install Wheel in Tire 4304
Install Tire on Two-Piece Wheel 4306
Add Air to Pneumatic Tires With Tube 4307
Install the Wheels 4308
Dual Drive Wheels, Install 4308
Pneumatic Tubeless Tire, Repair 4309
Remove Wheels From Lift Truck 4309
Add Air to Pneumatic Tubeless Tire 4314
Wheels, Install 4314
Solid Rubber Tires on Pneumatic Wheels, Change 4314
Snap-On-Tire, Change 4318
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 4321
Adhesives and Sealants 4325
524289374 0900YRM1326 (04 2018) UK EN 4329
General 4335
LPG Tank and Bracket Replacement 4335
Remove LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4335
Install LPG Tank for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4337
Remove LPG Tank for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4338
LPG Tank Install for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4340
Remove LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4341
Install LPG Bracket for Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4343
Remove LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4344
Install LPG Tank Bracket Alignment Pin, Lift Truck Models GLC030VX, GLC035VX, GLC040SVX (C809), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GLC040-070VX, GLC055SVX) (A910), and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 4346
Remove LPG Bracket for Lift Truck Models and GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4347
Install LPG Bracket for Lift Truck Models GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974) 4347
Fuel Filter Unit Repair 4347
Fuel Filter Element 4347
Remove 4347
Clean/Inspect 4348
Install 4348
Fuel Filter Housing 4348
Remove 4348
Disassemble 4351
Assemble 4353
Install 4354
Electronic Throttle Body Repair 4354
Remove 4354
Install 4356
Electronic Pressure Regulator (EPR) Repair 4356
Remove 4357
Disassemble 4361
Assemble 4363
Install 4364
LPG Shutoff Valve Assembly 4364
Remove 4364
Install 4368
Fuel Mixer Repair 4370
Remove 4370
Install 4373
Control System 4373
Engine Control Unit (ECU) 4373
Remove 4373
Install 4375
Low LPG Pressure Switch 4375
Remove 4375
Install 4376
LPG Low Level Sensor 4376
Remove 4377
Install 4380
Exhaust System 4381
Counterweight Exhaust System 4381
Remove and Disassemble 4381
Inspect 4383
Assemble and Install 4383
Overhead Exhaust System 4383
Remove and Disassemble 4384
Inspect 4386
Assemble and Install 4386
Exhaust Manifold 4387
Remove 4387
Install 4388
Positive Crankcase Ventilation (PCV) Valve 4389
Remove 4389
Inspect 4389
Install 4389
Oxygen Sensor 4389
Remove 4389
Install 4391
LPG Fuel Testing 4392
General 4392
Available Fuel Tests 4392
Composition Test (ASTM D-2163) 4392
Ammonia Test (ASTM D-4490) 4392
Basic Nitrogen Test (ASTM UOP269-90) 4392
Residues Test (ASTM D-2158) 4392
Vapor Pressure Test (ASTM D-2598) 4392
Sulfur Compounds Test (ASTM D-5623) 4393
Methanol Test (ASTM D-4864) 4393
Copper Corrosion (ASTM D-1838) 4393
Where To Send LPG Fuel Samples For Testing 4393
524289375 2200YRM1327 (09 2012) UK EN 4397
General 4401
Ignition System 4401
General 4401
Ignition Timing Adjustment, Gasoline and LPG 4401
Spark Plugs Check 4406
Spark Plug Wires Check 4406
Coil Replacement 4407
Remove 4407
Inspect 4408
Install 4408
Starter Repair 4409
General 4409
Remove 4409
No-Load Test 4410
Magnetic Switch Test 4411
Pull-Out Test 4411
Holding Coil Test 4411
Return Test 4411
Pinion Movement Inspection 4412
Install 4412
Alternator Repair 4412
General 4412
Charging System Inspection 4414
Output Current Check 4414
No-Load Adjusted Voltage Check 4415
Remove 4416
Inspect 4416
Rectifier Check 4416
Install 4417
Engine Sensors and Switches 4418
Oil Pressure Sensor, Gas and LPG Engines 4418
Remove 4418
Install 4418
Air Filter Restriction Switch, Gas and LPG Engines 4418
Remove 4418
Install 4418
Cam Angle Sensor, Gas and LPG Engines 4419
Remove 4419
Install 4420
Voltage Check 4420
Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines 4421
Remove 4421
Install 4422
Intake Air Temperature (IAT) Sensor, LPG Engines 4423
Remove 4423
Install 4423
Intake Air Temperature (IAT) Sensor, Gas Engines 4423
Remove 4423
Install 4423
Fuel Temperature Sensor, LPG Engines 4426
Remove 4426
Install 4426
Engine Coolant Temperature (ECT) Sensor 4427
2007 Emissions Compliant Gas Engines 4427
Remove 4427
Install 4427
2007 and 2010 Emissions Compliant LPG Engines 4428
Remove 4428
Install 4428
2010 Emissions Compliant Gas and LPG Engines 4430
Remove 4430
Install 4430
524306203 0100YRM1290 (04 2014) UK EN 4435
524329117 8000YRM1387 (03 2020) UK EN 4539
General Information About Diagrams and Schematics 4543
Symbol Definitions 4543
Diagrams Manual Applications 4544
Diagrams and Schematics 4546
550001092 8000YRM1409 (03 2020) UK EN 4611
General Information About Diagrams and Schematics 4615
Symbol Definitions 4615
Diagrams Manual Applications 4616
Diagrams and Schematics 4618
550010194 1300YRM1421 (08 2013) UK EN 4699
toc 4699
Single Speed PowerShift 4699
Safety Precautions Maintenance and Repair 4700
General 4703
Serial Number 4703
Hydraulic Gear Pump 4704
Remove 4704
Install 4704
Charge Pump Repair 4705
Original Charge Pump 4705
Remove 4705
Disassemble 4706
Clean 4706
Inspect 4706
Assemble 4706
Install 4706
New Charge Pump, Manufactured After July, 2013 4707
Remove 4707
Clean 4708
Inspect 4708
Install 4709
Torque Converter Replacement 4711
Remove 4711
Clean and Inspect 4711
Install 4711
Stator Support Assembly Repair 4712
Remove 4712
Disassemble 4717
Clean 4718
Inspect 4718
Assemble 4719
Install 4719
Clutch Packs Repair 4721
Remove 4721
Engine, Torque Converter, and Transmission Assembly 4721
Transmission Components 4722
Disassemble 4724
Transmission 4724
Housings 4724
Forward Clutch Pack 4727
Reverse Clutch Pack 4732
Clean 4738
Inspect 4738
Assemble 4739
Transmission 4739
Reverse Clutch Pack 4739
Forward Clutch Pack 4746
Housings 4752
Install 4754
Transmission Components 4754
Engine, Torque Converter, and Transmission Assembly 4757
Inching Overlap Adjustment 4757
Proportional and Enable Solenoid Valves 4758
Proportional Valves 4758
Remove 4758
Disassemble 4760
Clean and Inspect 4760
Assemble 4760
Install 4760
Enable Solenoid Valve 4760
Remove 4760
Disassemble 4760
Clean and Inspect 4760
Assemble 4761
Install 4761
Foot Directional Control Pedal Repair 4761
Remove and Disassembly 4761
Clean and Inspect 4765
Assemble and Install 4765
550030170 1300YRM1447 (08 2013) UK EN 4769
toc 4769
Single Speed Powershift 4769
Safety Precautions Maintenance and Repair 4770
General 4773
Serial Number 4773
Hydraulic Gear Pump 4774
Remove 4774
Install 4774
Housing Fittings Replacement 4774
Remove 4774
Disassemble 4775
Assemble 4775
Install 4775
Charge Pump Repair 4775
Lift Trucks Manufactured Before July, 2013 4775
Remove 4775
Disassemble 4777
Clean 4777
Inspect 4777
Assemble 4777
Install 4777
Lift Trucks Manufactured After July, 2013 4779
Remove 4779
Clean 4779
Inspect 4779
Install 4780
Torque Converter Replacement 4783
Remove 4783
Clean and Inspect 4783
Install 4783
Stator Support Assembly Repair 4785
Remove 4785
Disassemble 4790
Clean 4794
Inspect 4794
Assemble 4795
Install 4795
Clutch Packs Repair 4798
Remove 4798
Disassemble 4799
Housings 4799
Clutch Packs 4804
Forward Clutch Pack 4804
Reverse Clutch Pack 4809
Clean 4815
Inspect 4815
Assemble 4816
Clutch Packs 4816
Reverse Clutch Pack 4816
Forward Clutch Pack 4823
Housings 4830
Install 4830
Drive Chains and Sprockets 4836
Remove 4836
Clean 4838
Inspect 4838
Install 4838
Proportional and Enable Solenoid Valves 4839
Proportional Valves 4839
Remove 4839
Disassemble 4839
Clean and Inspect 4839
Assemble 4842
Install 4842
Enable Solenoid Valve 4842
Remove 4842
Disassemble 4843
Clean and Inspect 4843
Assemble 4843
Install 4843
Foot Directional Control Pedal Repair 4845
Remove and Disassemble 4845
Clean and Inspect 4849
Assemble and Install 4849
550031265 2000YRM1457 (10 2015) UK EN 4855
General 4859
Main Control Valve Repair 4861
Remove 4861
Main Control Valve Sections 4864
General 4864
Outlet Control Valve Section 4864
Remove 4864
Disassemble 4864
Clean 4864
Inspect 4864
Assemble 4866
Install 4866
Auxiliary Control Valve Section 4866
Remove 4866
Disassemble 4866
Clean 4868
Inspect 4868
Assemble 4868
Install 4868
Tilt Control Valve Section 4869
Remove 4869
Disassemble 4869
Clean 4869
Inspect 4869
Assemble 4870
Install 4871
Lift/Lower Control Valve Section 4871
Remove 4871
Disassemble 4871
Clean 4871
Inspect 4871
Assemble 4872
Install 4873
Transition Section 4873
Remove 4873
Disassemble 4873
Clean 4873
Inspect 4873
Assemble 4874
Install 4874
Install 4875
Pressure Relief Valve Check and Adjustment 4879
General 4879
Secondary Relief Valve 4879
Steering Control Unit Repair 4880
Remove 4881
Disassemble 4881
Clean 4885
Inspect 4885
Assemble 4885
Install 4886
System Relief Valve 4887
Disassemble 4887
Clean 4887
Inspect 4887
Assemble 4887
Accumulator Replacement 4888
Remove 4888
Install 4888
550043436 1300YRM1529 (11 2018) UK EN 4893
General 4897
Serial Number 4897
Charge Pump Repair 4897
Lift Trucks Manufactured Before July, 2013 4897
Remove 4897
Inspect 4897
Install 4897
Lift Trucks Manufactured After July, 2013 4898
Remove 4898
Inspect 4898
Install 4898
Torque Converter Replace 4899
Remove 4899
Install 4908
Housings and Chain Drive Repair 4914
Remove 4914
Clean 4925
Inspect 4925
Install 4925
Clutch Packs Repair 4932
Remove and Disassemble 4932
Transmission, Remove and Disassemble 4932
Clean 4951
Inspect 4951
Assemble and Install 4952
Transmission, Assemble and Install 4960
Control Valve Repair 4964
Remove and Disassemble 4964
Clean 4968
Inspect 4968
Assemble and Install 4968
Foot Directional Control Pedal Repair 4969
Remove and Disassemble 4969
Assemble and Install 4973
Direction Control Lever 4974
Remove 4974
Install 4974
550055283 8000YRM1585 (07 2020) UK EN 4979
General Information About Diagrams and Schematics 4983
Symbol Definitions 4983
Diagrams Manual Applications 4984
Diagrams and Schematics 4986
550073240 1900YRM1620 (01 2023) US EN 5075
Proper Flushing after Major Hydraulic Repairs 5081
Introduction 5081
The Phases of Wear 5081
Causes of Hydraulic System Failure 5081
Progression of Contaminant Caused Hydraulic System Failure 5082
Hydraulic System Flushing Techniques 5082
Double Oil and Filter Change 5082
Mechanical Cleaning 5083
Cleaning of Components 5083
How to Clean Tubes and Hoses 5083
Filter Caddy 5083
Start-Up Procedure for Cleaned System 5084
Contaminated Oil Coolers 5084
Additional Filter Caddy Functions 5085
How to Handle Different Fluids 5085
Water Removal Filters 5085
Fluid Conditioning and System Flushing Procedures 5086
Operation of the Filter Caddy 5086
Filter Caddy operation 5086
Fluid Conditioning Procedure 5086
Filter Caddy Start-Up 5087
System Flushing Procedure 5087
Component Cleaning Procedure 5088
Reservoir Cleaning Procedure 5088
Cylinder Cleaning Procedure 5088
Hose and Tube Cleaning Procedure 5088
Valve Cleaning Procedure 5089
Front-End Attachment Cleaning Procedure 5090
System Flushing Procedure 5090
Filter Caddy Start-Up 5091
System Start-Up and Flushing 5091
Reservoir Fluid Cleaning Times 5092
Dealing With Different Fluid Types 5093
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5093
Filter Caddy Maintenance 5093
Servicing the Strainer 5093
DC Motor 5093
Hydraulic Oil Sampling Method and Procedure 5094
Hydraulic Oil Sampling Method 5094
Objective 5094
General Guidelines 5094
Synopsis 5095
Hydraulic Oil Analysis Report Guidelines 5096
Sampling Conditions 5096
Equipment 5096
Sampling Procedure 5097
Hydraulic Oil Sampling 5097
Sample Labeling 5097
Results Documentation 5097
550073240 1900YRM1620 (03 2020) UK EN 5099
Proper Flushing after Major Hydraulic Repairs 5103
Introduction 5103
The Phases of Wear 5103
Causes of Hydraulic System Failure 5103
Progression of Contaminant Caused Hydraulic System Failure 5104
Hydraulic System Flushing Techniques 5104
Double Oil and Filter Change 5104
Mechanical Cleaning 5105
Cleaning of Components 5105
How to Clean Tubes and Hoses 5105
Filter Caddy 5105
Start-Up Procedure for Cleaned System 5106
Contaminated Oil Coolers 5106
Additional Filter Caddy Functions 5106
How to Handle Different Fluids 5106
Water Removal Filters 5107
Fluid Conditioning and System Flushing Procedures 5107
Operation of the Filter Caddy 5107
Filter Caddy operation 5107
Fluid Conditioning Procedure 5108
Filter Caddy Start-Up 5108
System Flushing Procedure 5109
Component Cleaning Procedure 5109
Reservoir Cleaning Procedure 5109
Cylinder Cleaning Procedure 5109
Hose and Tube Cleaning Procedure 5110
Valve Cleaning Procedure 5110
Front-End Attachment Cleaning Procedure 5111
System Flushing Procedure 5111
Filter Caddy Start-Up 5112
System Start-Up and Flushing 5112
Reservoir Fluid Cleaning Times 5113
Dealing With Different Fluid Types 5113
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 5113
Filter Caddy Maintenance 5114
Servicing the Strainer 5114
DC Motor 5114
Hydraulic Oil Sampling Method and Procedure 5114
Hydraulic Oil Sampling Method 5114
Objective 5114
General Guidelines 5114
Synopsis 5115
Hydraulic Oil Analysis Report Guidelines 5116
Sampling Conditions 5117
Equipment 5117
Sampling Procedure 5117
Hydraulic Oil Sampling 5117
Sample Labeling 5118
Results Documentation 5118
550093750 2100YRM1668 (02 2018) UK EN 5121
General 5125
Safety Procedures When Working Near Mast 5126
Main Lift Cylinder Repair 5128
Remove 5128
Disassemble 5130
Clean 5132
Inspect 5132
Assemble 5132
Install 5133
Main Lift Cylinder Leak Check 5133
Free-Lift Cylinder 5134
Remove 5134
Disassemble 5135
Clean 5137
Inspect 5137
Assemble 5137
Install 5137
Tilt Cylinder Repair 5138
Remove 5138
Disassemble 5140
Clean 5142
Inspect 5142
Assemble 5142
Install 5143
Tilt Cylinder Adjustment 5144
Tilt Cylinder Leak Check 5145
Integral Sideshift Cylinder Repair Prior to December 2016 5147
Remove 5147
Disassemble 5148
Clean 5149
Inspect 5149
Assemble 5149
Install 5149
Integral Sideshift Cylinder Repair After December 2016 5150
General 5150
Remove 5150
Disassemble 5152
Clean 5152
Inspect 5152
Assemble 5152
Install 5153
Integral Side-Shift Cylinder Gland Leak Checks 5154
Fork Positioner Cylinder Repair Prior to December 2016 5155
Remove 5155
Disassemble 5155
Clean 5157
Inspect 5158
Assemble 5158
Install 5158
Fork Positioner Cylinder Adjustment 5158
Fork Positioner Cylinder Repair After December 2016 5159
General 5159
Remove 5159
Disassemble 5159
Clean 5162
Inspect 5163
Assemble 5163
Install 5163
Fork Positioner Cylinder Adjustment 5163
Seal Kit Installation 5164
External Installation (Seal and Backup Ring) 5164
Internal Installation (Piston Rod Assembly) 5164
Torque Specifications 5165
Main Lift Cylinders 5165
Free-Lift Cylinder 5165
Tilt Cylinders 5165
Integral Sideshift Cylinder 5165
Fork Positioner Cylinder 5165
550093750 2100YRM1668 (04 2023) US EN 5169
General 5175
Safety Procedures When Working Near Mast 5178
Main Lift Cylinder Repair 5180
Remove 5180
Disassemble 5182
Clean 5184
Inspect 5184
Assemble 5184
Install 5185
Main Lift Cylinder Leak Check 5185
Free-Lift Cylinder 5186
Remove 5186
Disassemble 5187
Clean 5189
Inspect 5189
Assemble 5189
Install 5189
Tilt Cylinder Repair 5191
Remove 5191
Disassemble 5193
Clean 5194
Inspect 5195
Assemble 5195
Install 5196
Tilt Cylinder Adjustment 5196
Tilt Cylinder Leak Check 5198
Integral Sideshift Cylinder Repair Prior to December 2016 5200
Remove 5200
Disassemble 5200
Clean 5201
Inspect 5201
Assemble 5201
Install 5202
Integral Sideshift Cylinder Repair After December 2016 5203
General 5203
Remove 5203
Disassemble 5204
Clean 5205
Inspect 5205
Assemble 5205
Install 5205
Integral Side-Shift Cylinder Gland Leak Checks 5206
Fork Positioner Cylinder Repair Prior to December 2016 5207
Remove 5207
Disassemble 5207
Clean 5210
Inspect 5210
Assemble 5211
Install 5211
Fork Positioner Cylinder Adjustment 5211
Fork Positioner Cylinder Repair After December 2016 5213
General 5213
Remove 5213
Disassemble 5213
Clean 5216
Inspect 5216
Assemble 5217
Install 5217
Fork Positioner Cylinder Adjustment 5217
Seal Kit Installation 5219
External Installation (Seal and Backup Ring) 5219
Internal Installation (Piston Rod Assembly) 5219
Torque Specifications 5220
Main Lift Cylinders 5220
Free-Lift Cylinder 5220
Tilt Cylinders 5220
Integral Sideshift Cylinder 5220
Fork Positioner Cylinder 5220
550093755 4000YRM1669 (06 2019) UK EN 5223
General 5229
Safety Procedures When Working Near Mast 5230
Fork Replacement 5232
Standard Carriage and Integral Sideshift Carriage 5232
Remove 5232
Install 5234
Checks 5234
Fork Positioner Carriage 5236
Remove 5237
Install 5237
Checks 5239
Carriages Repair, Two-Stage LFL Mast 5241
Standard Carriage 5241
Remove 5241
Clean and Inspect 5242
Install 5243
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5243
Remove 5243
Disassemble 5244
Clean and Inspect 5245
Assemble 5246
Install 5246
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 through Late June, 2018 5247
Remove 5247
Disassemble 5250
Clean and Inspect 5250
Assemble 5251
Install 5251
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5252
Remove 5252
Disassemble 5255
Clean and Inspect 5255
Assemble 5256
Install 5256
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5257
Remove 5257
Install 5259
Fork Positioner Hydraulic Hose Adjustment 5261
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5262
Remove 5262
Disassemble and Assemble 5266
Clean and Inspect 5266
Install 5266
Fork Positioner Hydraulic Hose Adjustment 5267
Fork Positioner Carriage, Lift Trucks Manufactured Late June, 2018 and After 5268
Remove 5268
Disassemble and Assemble 5272
Clean and Inspect 5272
Install 5272
Fork Positioner Hydraulic Hose Adjustment 5273
Two-Stage LFL Mast Repair 5274
Mast With Serial Number F507 5274
Remove 5274
Disassemble 5278
Clean and Inspect 5285
Assemble 5287
Install 5288
Header Hoses 5290
Remove 5290
Installation 5290
Adjustment 5294
Mast With Serial Number F562 5295
Remove 5295
Disassemble 5299
Clean and Inspect 5306
Assemble 5308
Install 5309
Header Hose Installation and Adjustment 5310
Remove 5310
Installation 5311
Adjustment 5315
Carriages Repair, Three-Stage FFL Mast 5316
Standard Carriage 5316
Remove 5316
Clean and Inspect 5318
Install 5318
Integral Sideshift Carriage, Lift Trucks Manufactured Prior To December, 2016 5318
Remove 5318
Disassemble 5320
Clean and Inspect 5321
Assemble 5322
Install 5322
Integral Sideshift Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5323
Remove 5323
Disassemble 5325
Clean and Inspect 5326
Assemble 5327
Install 5327
Integral Sideshift Carriage, Lift Trucks Manufactured Late June, 2018 and After 5328
Remove 5328
Disassemble 5330
Clean and Inspect 5331
Assemble 5332
Install 5332
Fork Positioner Carriage, Lift Trucks Manufactured Prior To December, 2016 5333
Remove 5333
Install 5335
Fork Positioner Hydraulic Hose Adjustment 5337
Fork Positioner Carriage, Lift Trucks Manufactured December, 2016 Through Late June, 2018 5338
Remove 5338
Disassemble and Assemble 5340
Clean and Inspect 5340
Install 5340
Fork Positioner Hydraulic Hose Adjustment 5341
Fork Positioner Carriage, Lift Trucks Manufactured After Late June, 2018 5342
Remove 5342
Disassemble and Assemble 5345
Clean and Inspect 5345
Install 5345
Fork Positioner Hydraulic Hose Adjustment 5346
Three-Stage FFL Mast Repair 5347
Mast With Serial Number F508 5347
Remove 5347
Disassemble 5351
Clean and Inspect 5361
Assemble 5364
Install 5365
Header Hose Installation and Adjustment 5367
Remove 5367
Installation 5367
Adjustment 5375
Mast With Serial Number F563 5376
Remove 5376
Disassemble 5379
Clean and Inspect 5389
Assemble 5392
Install 5393
Header Hose Installation and Adjustment 5395
Remove 5395
Installation 5395
Adjustment 5403
Mast Adjustments 5404
Load Roller, Adjust 5404
Mast Side Kicking, Adjust 5406
Carriage Adjustments 5406
Lift Chains Adjustment 5408
Hydraulic Quick Disconnect Hoses 5410
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5410
Lift Trucks Equipped With E-Hydraulic Controls 5410
Lift Trucks Equipped With Manual Hydraulic Controls 5411
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models GLC020-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910, B910, C910) and GLP/GDP20-35VX (CP/CLP/CDP040-070VX) (B875, C875, D875) 5411
Lift Trucks Equipped With E-Hydraulic Controls 5411
Lift Trucks Equipped With Manual Hydraulic Controls 5412
Disconnecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5412
Connecting Attachment Hydraulic Quick Disconnect Hoses, Lift Truck Models ERC22-35VG (ERC045-070VG) (A968) and ERP22-35VL (ERP045-070VL) (A976) 5412
More products
